US7550360B2 - Solid electrolytic capacitor manufacturing method capable of easily and properly connecting anode electrode portion - Google Patents
Solid electrolytic capacitor manufacturing method capable of easily and properly connecting anode electrode portion Download PDFInfo
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- US7550360B2 US7550360B2 US11/820,304 US82030407A US7550360B2 US 7550360 B2 US7550360 B2 US 7550360B2 US 82030407 A US82030407 A US 82030407A US 7550360 B2 US7550360 B2 US 7550360B2
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- anode electrode
- solid electrolytic
- conductive paste
- metal base
- electrolytic capacitor
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- 239000003990 capacitor Substances 0.000 title claims abstract description 76
- 239000007787 solid Substances 0.000 title claims abstract description 50
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 21
- 229910052751 metal Inorganic materials 0.000 claims abstract description 51
- 239000002184 metal Substances 0.000 claims abstract description 51
- 239000010407 anodic oxide Substances 0.000 claims abstract description 31
- 239000007784 solid electrolyte Substances 0.000 claims abstract description 22
- 229920001940 conductive polymer Polymers 0.000 claims abstract description 9
- 238000000034 method Methods 0.000 claims description 22
- 239000000853 adhesive Substances 0.000 claims description 17
- 230000001070 adhesive effect Effects 0.000 claims description 17
- 230000001678 irradiating effect Effects 0.000 claims description 5
- 230000003647 oxidation Effects 0.000 claims description 5
- 238000007254 oxidation reaction Methods 0.000 claims description 5
- 239000011248 coating agent Substances 0.000 claims description 4
- 238000000576 coating method Methods 0.000 claims description 4
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 abstract description 31
- 229910052709 silver Inorganic materials 0.000 abstract description 30
- 239000004332 silver Substances 0.000 abstract description 30
- 229910052782 aluminium Inorganic materials 0.000 abstract description 29
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 abstract description 29
- 238000003466 welding Methods 0.000 description 20
- NDVLTYZPCACLMA-UHFFFAOYSA-N silver oxide Chemical compound [O-2].[Ag+].[Ag+] NDVLTYZPCACLMA-UHFFFAOYSA-N 0.000 description 6
- 230000005856 abnormality Effects 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 239000012212 insulator Substances 0.000 description 4
- 229920005989 resin Polymers 0.000 description 4
- 239000011347 resin Substances 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- 229910002804 graphite Inorganic materials 0.000 description 3
- 239000010439 graphite Substances 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 238000007650 screen-printing Methods 0.000 description 3
- 229910001923 silver oxide Inorganic materials 0.000 description 3
- KAESVJOAVNADME-UHFFFAOYSA-N Pyrrole Chemical compound C=1C=CNC=1 KAESVJOAVNADME-UHFFFAOYSA-N 0.000 description 2
- 239000003985 ceramic capacitor Substances 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- 239000011244 liquid electrolyte Substances 0.000 description 2
- NUJOXMJBOLGQSY-UHFFFAOYSA-N manganese dioxide Chemical compound O=[Mn]=O NUJOXMJBOLGQSY-UHFFFAOYSA-N 0.000 description 2
- 230000000149 penetrating effect Effects 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- ROOXNKNUYICQNP-UHFFFAOYSA-N ammonium persulfate Chemical compound [NH4+].[NH4+].[O-]S(=O)(=O)OOS([O-])(=O)=O ROOXNKNUYICQNP-UHFFFAOYSA-N 0.000 description 1
- 239000012935 ammoniumperoxodisulfate Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000011231 conductive filler Substances 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000002019 doping agent Substances 0.000 description 1
- 239000003792 electrolyte Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 238000009499 grossing Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 150000002894 organic compounds Chemical class 0.000 description 1
- 239000007800 oxidant agent Substances 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- JOXIMZWYDAKGHI-UHFFFAOYSA-N toluene-4-sulfonic acid Chemical compound CC1=CC=C(S(O)(=O)=O)C=C1 JOXIMZWYDAKGHI-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
- H01G9/004—Details
- H01G9/008—Terminals
- H01G9/012—Terminals specially adapted for solid capacitors
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
- H01G9/15—Solid electrolytic capacitors
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
- H01G9/004—Details
- H01G9/04—Electrodes or formation of dielectric layers thereon
Definitions
- This invention relates to a method of manufacturing a thin-type solid electrolytic capacitor using a flat plate-shaped aluminum foil or the like and, in particular, relates to a method of manufacturing a solid electrolytic capacitor having a low impedance.
- electrolytic capacitors are strongly required to be small in size, large in capacitance, and low in ESR (Equivalent Series Resistance) or low in impedance.
- a conventional electrolytic capacitor using a liquid or solid electrolyte is inferior to a multilayer ceramic capacitor in characteristic in a high frequency region and thus cannot sufficiently satisfy the foregoing requirement.
- JP-A Japanese Unexamined Patent Application Publication
- JP-A Japanese Unexamined Patent Application Publication
- JP-A Japanese Unexamined Patent Application Publication
- Hei 09-36003 discloses a multilayer solid electrolytic capacitor formed by stacking a plurality of solid electrolytic capacitors each using as a solid electrolyte a conductive polymer film formed on a dielectric oxide film and each using aluminum as an anode body. Electrical connection between anode electrode portions of the solid electrolytic capacitors or between anode electrode portions and lead frames of the solid electrolytic capacitors is carried out by electrical spot welding, laser welding, or the like.
- the resistivity of a conductive polymer is lower by one or two digits as compared with that of a conventional liquid or solid electrolyte. Therefore, by setting the rate of a cathode electrode portion accounting for in the whole to be large and setting the rate of an anode electrode portion accounting for in the whole to be small, it is possible to achieve a low impedance equivalent to that of a multilayer ceramic capacitor in a high frequency region.
- the anode electrode portion is small, damage to a dielectric oxide film tends to occur by a welding operation to the anode electrode portion and thus there may occur a case where the leakage current of the solid electrolytic capacitor increases.
- the welding is performed by accurately positioning welding points so as to be adapted to the size of the anode electrode portion, its connection strength becomes insufficient.
- connection strength at the anode electrode portion after the laser welding may become small or the connection resistance at the anode electrode portion after the laser welding may become large.
- a method of manufacturing a solid electrolytic capacitor comprising a surface-roughened flat plate-shaped metal base, an anodic oxide film formed by anodic oxidation on a surface of the metal base, a solid electrolyte layer formed of a conductive polymer at at least a portion on the anodic oxide film, a cathode electrode portion formed on the solid electrolyte layer, and an anode electrode portion formed at a portion, where the solid electrolyte layer is not provided, of the metal base, the method comprising coating a conductive paste on the anodic oxide film on one side of the metal base and curing the conductive paste coated, thereby forming a metal layer, and irradiating a laser beam from a side, opposite to the one side where the conductive paste is coated, of the metal base to weld together the metal base and the metal layer, thereby forming the anode electrode portion.
- a method of manufacturing a solid electrolytic capacitor comprising preparing a plurality of capacitor elements each in the form of the solid electrolytic capacitor manufactured by the method mentioned in the above clause, and bonding together the anode electrode portions of the plurality of capacitor elements using a conductive adhesive.
- a method of manufacturing a solid electrolytic capacitor comprising a plurality of capacitor elements each comprising a surface-roughened flat plate-shaped metal base, an anodic oxide film formed by anodic oxidation on a surface of the metal base, a solid electrolyte layer formed of a conductive polymer at at least a portion on the anodic oxide film, a cathode electrode portion formed on the solid electrolyte layer, and an anode electrode portion formed at a portion, where the solid electrolyte layer is not provided, of the metal base, the method comprising coating a conductive paste on the anodic oxide film on one side of the metal base and curing the conductive paste coated, thereby forming a metal layer in each of the plurality of capacitor elements, and irradiating a laser beam from a side, opposite to the one side where the conductive paste is coated, of the metal base to weld together the metal base and the metal layer, thereby forming the anode
- FIG. 1 is a process diagram for explaining a solid electrolytic capacitor manufacturing method according to exemplary embodiment 1 of this invention
- FIG. 2 is a plan view of a solid electrolytic capacitor manufactured by the manufacturing method explained with reference to FIG. 1 ;
- FIG. 3 is a sectional view taken along line III-III in FIG. 2 ;
- FIG. 4 is a sectional view, similar to FIG. 3 , of a multilayer solid electrolytic capacitor manufactured by a manufacturing method according to exemplary embodiment 2 of this invention.
- a flat plate-shaped metal base specifically, a flat plate-shaped aluminum base 2 is prepared to have surfaces roughened by porosity formation.
- anodic oxide films 1 are formed by anodic oxidation on the surfaces of the flat plate-shaped aluminum base 2 , respectively.
- two insulator layers 4 made of an epoxy resin or the like are formed at predetermined positions on the anodic oxide film 1 , specifically, near both end portions of the anodic oxide film 1 .
- FIG. 1 two insulator layers 4 made of an epoxy resin or the like are formed at predetermined positions on the anodic oxide film 1 , specifically, near both end portions of the anodic oxide film 1 .
- a solid electrolyte layer 5 is formed of a conductive polymer at at least a portion on each of the anodic oxide films 1 , specifically, in a region between the two insulator layers 4 on the surfaces of the anodic oxide film 1 .
- a graphite layer 6 and a silver paste layer 7 are formed on each solid electrolyte layer 5 in the order named, thereby forming a cathode electrode portion 3 on each electrolyte layer 5 .
- a silver paste being a conductive paste is coated on the anodic oxide film 1 on one side of the aluminum base 2 and then cured, thereby forming metal silver layers 9 at both end portions of the anodic oxide film 1 , respectively.
- a laser beam is irradiated from the side, opposite to the side where the conductive paste is coated, of the aluminum base 2 to fusion-bond or weld together the aluminum base 2 and each of the metal silver layers 9 at a plurality of welding portions 10 , thereby forming anode electrode portions 8 as shown in FIGS. 2 and 3 .
- a solid electrolytic capacitor was manufactured by a manufacturing method which will be described hereinbelow.
- An aluminum base 2 formed with porous anodic oxide films 1 by setting a chemical conversion voltage to 3V and having a unit area capacitance of 270 ⁇ F/cm 2 and a thickness of 70 microns was cut into a shape with a width of 4.2 mm and a length of 5 mm.
- Insulator layers 4 were formed so as to allow cathode electrode portions 3 to have a width of 4.2 mm and a length of 3.5 mm.
- the insulator layers 4 each had a width of 0.25 mm and a thickness of 30 ⁇ m and were formed by screen printing of an epoxy resin.
- a solid electrolyte layer 5 of a conductive polymer having a conductivity of 50 S/cm or more was formed by reacting pyrrole as a monomer, ammonium peroxodisulfate as an oxidant, and paratoluenesulfonic acid as a dopant at the composition ratio of 6:1:2, respectively.
- a graphite layer 6 having a thickness of 10 ⁇ m and a silver paste layer 7 having a thickness of 30 ⁇ m were coated in the order named by screen printing.
- each of the cathode electrode portions 3 was formed to comprise the solid electrolyte layer 5 , the graphite layer 6 , and the silver paste layer 7 .
- a silver paste was coated by screen printing on the anodic oxide film 1 on one side of the aluminum base 2 and then cured, thereby forming metal silver layers 9 .
- the aluminum base 2 and each of the metal silver layers 9 were welded together by perpendicularly irradiating a YAG laser beam onto the opposite side, i.e. the lower side in FIG. 1 , (e), of the aluminum base 2 , thereby forming anode electrode portions 8 .
- a conductive paste containing 20 to 30% organic silver and containing, as a filler, silver oxide particles having a particle size of 1 ⁇ m or less is coated using a screen mask so that the thickness of the coated conductive paste after curing becomes 10 to 20 microns.
- the metal silver layers 9 are obtained through a reaction between the organic silver and the silver oxide. In each metal silver layer 9 after the curing, the content of remaining organic components is 3.5%.
- each of the anode electrode portions 8 and an external anode terminal, and the cathode electrode portion 3 and an external cathode terminal were bonded together using a conductive paste such as a conductive adhesive. Further, all portions other than drawing portions of the external anode terminals and the external cathode terminal were molded by a resin, thereby obtaining a solid electrolytic capacitor.
- the obtained solid electrolytic capacitor had characteristics such that the capacitance at a frequency of 120 Hz was 25 ⁇ F, the ESR at a frequency of 100 kHz was 10 m ⁇ , and the leakage current was 5 ⁇ A. It was confirmed that the obtained solid electrolytic capacitor was small in size and had low impedance characteristics and, further, the anode electrode portions had sufficient strength.
- each metal silver layer 9 formed of the coated conductive paste and the aluminum base 2 adhere to each other, sufficient connection strength is obtained. Further, since each metal silver layer 9 is mostly formed of the conductive filler in the conductive paste, the electrical resistance between the welded metal silver layer 9 and aluminum base 2 is small. Therefore, it is possible to realize the aluminum solid electrolytic capacitor that achieves both a reduction in size and a reduction in impedance.
- the metal silver layer 9 contains a large amount of resin components
- the resin components burn due to laser irradiation to cause characteristic degradation of an electrolytic capacitor due to abnormality in welding shape, an increase in connection resistance, and so on.
- a conductive paste such that the content of organic components remaining in the paste after curing becomes less than 5%, preferably 4% or less.
- a nano silver paste in the form of silver particles of 0.1 ⁇ m or less in size there are cited a nano silver paste in the form of silver particles of 0.1 ⁇ m or less in size, an organic silver paste, a mixed paste of organic silver and silver oxide, and so on.
- a solid electrolytic capacitor as a comparative capacitor was manufactured using a conductive paste such that the content of organic compounds remaining in a metal silver layer 9 after curing at 150° C. or more is 5%.
- the welding shape abnormality rates and the electrical resistances at the anode electrode portions after the laser irradiation were evaluated and compared between the solid electrolytic capacitor (herein called “exemplary embodiment 1”) manufactured by the manufacturing method according to exemplary embodiment 1 and the comparative capacitor.
- the comparison results are shown in Table 1.
- FIG. 4 shows a solid electrolytic capacitor manufactured by a manufacturing method according to exemplary embodiment 2.
- This solid electrolytic capacitor comprises four solid electrolytic capacitors 21 , 22 , 23 , and 24 . Since each of the four solid electrolytic capacitors 21 , 22 , 23 , and 24 is manufactured by the manufacturing method described with reference to FIG. 1 and thus includes an aluminum base, such a solid electrolytic capacitor may also be hereinafter referred to as a “four-layer aluminum solid electrolytic capacitor”.
- each of the solid electrolytic capacitors 21 , 22 , 23 , and 24 a silver paste being a conductive paste was coated on an anodic oxide film 1 on one side of an aluminum base 2 and then cured, thereby forming metal silver layers 9 . Further, a laser beam is irradiated from the side, opposite to the side where the conductive paste is coated, of the aluminum base 2 to weld together the aluminum base 2 and each of the metal silver layers 9 , thereby forming anode electrode portions 18 .
- each of the metal silver layers 9 and the aluminum base 2 covered with the anodic oxide film 1 were welded together, thereby forming welding portions 10 .
- a cathode electrode portion of the solid electrolytic capacitor 21 and a cathode electrode portion of the solid electrolytic capacitor 22 were bonded together using a conductive adhesive 11 .
- the welding portions 10 of the anode electrode portions were simultaneously bonded using a similar conductive adhesive 12 .
- part of the conductive adhesive 12 was filled into the through hole-like welding portions 10 , the anode electrode portions of the solid electrolytic capacitor 21 and the anode electrode portions of the solid electrolytic capacitor 22 were also electrically connected together.
- the four solid electrolytic capacitors were stacked together by repeating the same process, thereby completing upper and lower cathode electrode portions 13 and anode electrode portions 18 of the four-layer aluminum solid electrolytic capacitor. Thereafter, each of the anode electrode portions 18 and an external anode terminal, and the cathode electrode portions 13 and an external cathode terminal were bonded together using a conductive adhesive. Further, all portions other than drawing portions of the external anode terminals and the external cathode terminal were molded by a resin, thereby obtaining the four-layer aluminum solid electrolytic capacitor.
- the obtained four-layer aluminum solid electrolytic capacitor had characteristics such that the capacitance at a frequency of 120 Hz was 100 ⁇ F, the ESR at a frequency of 100 kHz was 5 m ⁇ , and the leakage current was 20 ⁇ A. It was confirmed that the obtained four-layer aluminum solid electrolytic capacitor was small in size and had low impedance characteristics and, further, the anode electrode portions had sufficient strength.
- the conductive paste may be arranged such that the content of organic components remaining in the conductive paste after curing is less than 5%.
- the method may be arranged to comprise connecting an external anode terminal to the anode electrode portion using a conductive adhesive.
- the method may be arranged to comprise bonding together the cathode electrode portions of the plurality of capacitor elements using a conductive adhesive.
- the conductive paste may be arranged such that the content of organic components remaining in the conductive paste after curing is less than 5%.
- the method may be arranged to comprise connecting an external anode terminal to at least one of the anode electrode portions of the plurality of capacitor elements using a conductive adhesive.
- the method may be arranged to comprise bonding together the anode electrode portions of the plurality of capacitor elements using a conductive adhesive.
- the method may be arranged to comprise bonding together the cathode electrode portions of the plurality of capacitor elements using a conductive adhesive.
- the invention is not to be limited thereto.
- the layered structure, the thicknesses and materials of respective layers, the external shape, the shapes of cathode and anode electrode portions and laser irradiated portions, and so on of a solid electrolytic capacitor, to which this invention is applied can be changed depending on the required shape and characteristics and so on of the solid electrolytic capacitor.
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- Power Engineering (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Fixed Capacitors And Capacitor Manufacturing Machines (AREA)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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JP2006172511A JP4662368B2 (ja) | 2006-06-22 | 2006-06-22 | 固体電解コンデンサの製造方法 |
JP2006-172511 | 2006-06-22 |
Publications (2)
Publication Number | Publication Date |
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US20070297121A1 US20070297121A1 (en) | 2007-12-27 |
US7550360B2 true US7550360B2 (en) | 2009-06-23 |
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US11/820,304 Active US7550360B2 (en) | 2006-06-22 | 2007-06-18 | Solid electrolytic capacitor manufacturing method capable of easily and properly connecting anode electrode portion |
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US (1) | US7550360B2 (ja) |
JP (1) | JP4662368B2 (ja) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
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US20170287647A1 (en) * | 2016-03-31 | 2017-10-05 | Murata Manufacturing Co., Ltd. | Solid electrolytic capacitor |
US11211204B2 (en) * | 2017-09-23 | 2021-12-28 | Japan Capacitor Industrial Co., Ltd. | Solid electrolytic capacitor and method for manufacturing same |
US11244790B2 (en) * | 2019-03-28 | 2022-02-08 | Murata Manufacturing Co., Ltd. | Solid electrolytic capacitor and solid electrolytic capacitor manufacturing method |
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JP5104380B2 (ja) * | 2008-02-15 | 2012-12-19 | 日本ケミコン株式会社 | 固体電解コンデンサ及びその製造方法 |
JP5210672B2 (ja) * | 2008-03-18 | 2013-06-12 | Necトーキン株式会社 | コンデンサ部品 |
JP2009231337A (ja) * | 2008-03-19 | 2009-10-08 | Nec Tokin Corp | 固体電解コンデンサ |
JP2010040960A (ja) * | 2008-08-08 | 2010-02-18 | Nec Tokin Corp | 固体電解コンデンサ |
CN102854651B (zh) * | 2012-09-27 | 2015-07-15 | 豪威科技(上海)有限公司 | 反射式液晶面板及其制造方法 |
JP7067512B2 (ja) | 2019-03-22 | 2022-05-16 | 株式会社村田製作所 | 固体電解コンデンサ |
JP7408288B2 (ja) * | 2019-03-22 | 2024-01-05 | 株式会社村田製作所 | 固体電解コンデンサ |
CN110136865B (zh) * | 2019-04-29 | 2020-12-18 | 华中科技大学 | 一种基于激光焊接的大面积纳米柔性电极制备方法及产品 |
CN110373695B (zh) * | 2019-08-20 | 2024-06-14 | 丰宾电子科技股份有限公司 | 一种用于固体电解质铝电解电容器的电聚合电极盘 |
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JP2008004744A (ja) | 2008-01-10 |
US20070297121A1 (en) | 2007-12-27 |
JP4662368B2 (ja) | 2011-03-30 |
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